Pour depressant compositions of cracked ethylene/propylene/diene terpolymers

ABSTRACT

AN AMORPHOUS CRACKED ETHYLENE-PROPYLENE-TERPOLYMER POUR DEPRESSANT COMPOSITION CONSISTING OF 10 TO 90 PERCENT ETHYLENE, 5 TO 70 PERCENT PROPYLENE AND 0.1 TO 20 PERCENT OF A NON-CONJUGATED DIENE HAVING FROM 5 TO 30 CARBON ATOMS, AND A METHOD OF PREPARING SAME.

United States Patent US. Cl. 260-8058 4 Claims ABSTRACT OF THE DISCLOSURE An amorphous cracked ethylenepropylene-terpolymer pour depressant composition consisting of 10 to 90 percent ethylene, 5 to 70 percent propylene and 0.1 to 20 percent of a non-conjugated diene having from 5 to 30 carbon atoms, and a method of preparing same.

This invention relates to a pour depressant composition, to a mineral oil composition containing same and to a method for manufacturing the pour depressant. The pour depressant is effective for substantially reducing the pour point of fuel oils, diesel oils, middle distillates and other viscous hydrocarbon oils. The pour depressant composition of the invention is also useful as an additi-ve for gasoline wherein the composition acts as a modifier of induction system deposits.

The novel pour depressant composition of the invention comprises an amorphous, cracked, ethylene-propylene-terpolymer consisting of to 90 mole percent ethylene, 5 to 70 mole percent propylene and 0.1 to 20 mole percent of a non-conjugated diene having from 5 to 30 carbon atoms, the inherent viscosity of the cracked terpolymer being in the range of 0.2 to 0.9. The process of the invention involves reacting an amorphous ethylenepropylene-terpolymer of the above olefin monomer composition having an inherent viscosity of 1.1 or above under cracking conditions to produce an amorphous cracked terpolymer product having an inherent viscosity in the range of 0.2 to 0.9.

Heating oils, diesel fuels and liquid hydrocarbon oils employed in cold climates or exposed to low temperatures frequently require the use of an additive to maintain their fluidity or to meet critical pour point specifications for the oil in question. Additives that are effective for this are called pour depressants. While the art discloses numerous pour depressants, many are not entirely suitable because of their high cost or the high concentration required or because they do not lower the pour point to the required temperature. An effective pour depressant is one which will substantially reduce the pour point of a treated oil when used in a small concentration without imparting any undesirable efiects.

This is a division of application Ser. No. 571,970 filed Aug. 12, 1966 and now US. Pat. No. 3,499,741.

It has now been discovered that certain polymers which possess a moderate but unsatisfactory degree of pour depressant activity per se, can be converted to reaction products that are surprisingly effective at low concentration as pour depressants for mineral oil compositions. While the reasons for this are not fully understood it is believed that cracking of the terpolymer rearranges as well as shortens the polymers making them unexpectedly good pour depressors. This invention is directed to the novel pour depressant, to mineral oil compositions containing the pour depressant and to a method for making the pour depressant.

The pour depressant of this invention is an amorphous, cracked, ethylene-propylene-terpolymer, consisting of 3,681,302 Patented Aug. 1, 1972 ice polymerized ethylene, propylene and a non-conjugated diene having from '5 to 30 carbon atoms in the proportions of 10 to mole percent ethylene, 5 to 70 mole percent propylene and 0.1 to 20 mole percent of the diene having an inherent viscosity of from 0.2 to 0.9. Preferably, the pour depressant consists of from 50 to 90 mole percent ethylene, 5 to 45 mole percent propylene and 1 to 5 mole percent diene and has an inherent viscosity in the range of 0.3 to 0.6.

The inherent viscosity equals the natural log of the specific viscosity divided by the concentration in grams per one hundred ml. The specific viscosity for this equation is the expression of a ratio of the viscosity of the solution divided by the viscosity of the solvent (see Appendix D, p. 103, Report No. 4 in Polymer Chemistry by Robert Magovern, Stanford Research Institute, April 1965).

The pour depressant of the invention is prepared from an amorphous ethylene-propylene-terpolymer, consisting of ethylene, propylene and a non-conjugated diene having from 5 to 30 carbon atoms in the proportions of 10 to 90 mole percent ethylene, 5 to 70 mole percent propylene and 0.1 to 20 mole percent diene having an inherent viscosity of at least 1.1. The preferred starting terpolymer, however, is one consisting of 50 to 90 mole percent ethylene, 5 to 45 mole percent propylene and 1 to 5 mole percent of a non-conjugated diene having from 6 to 20 carbon atoms and having an inherent viscosity in the range of 1.1 to 5.

The terpolymers employed as the starting material are prepared by copolymerizing ethylene, propylene and diene in the stated proportions. The diene reactant is a nonconjugated diene having from 5 to 30 carbon atoms and preferably from 6 to 20 carbon atoms. Specific dienes which can be employed include bicyclo [2,2,1 ]hepta-2,5-diene, 1,4-cyclohexadiene, 1,5-cyclooctadiene, dicyclopentadiene, di-isopropenyl benzene, dipentene, 2,2-dimethyl-1,5-hexadiene, 1,5-heptadiene,

1,5-hexadiene, 2-methyl-1,4-cyclohexadiene, methyl cyclopentadiene dimer, S-methylene-Z-norbornene, 3-methyl-1,5-heptadiene, 2- methy1-1,5-hexadiene, 3-methyl-1,5-hexadiene, 1,7-octadiene,

1,4-pentadiene, 4-vinyl-1-cyclohexene, and 2-methyl-1,4-pentadiene.

The ethylene-propy1ene-terpolymers can be prepared by conventional polymerization methods. In general, a mixture of the ethylene, propylene and diene in a suitable solvent is polymerized under atmospheric or superatmospheric pressure in the presence of a catalyst, such as a Zeigler-Natta catalyst, to produce the amorphous terpolymer product. Terpolymers having a broadrange of inherent viscosities can be so prepared by varying the concentration of the olefin components, the concentration and specific nature of the catalyst employed as well as the polymerization reaction temperature and the time of reaction.

The terpolymer of prescribed composition must be cracked to produce the effective pour depressant of the invention. The terpolymer can be cracked by any conventional cracking process although thermal cracking is preferred. Thermal cracking is accomplished by heating the terpolymer to a temperature in the range of 250 to 450 C. and holding the terpolymer at the selected temperature until the copolymer has been cracked. Generally, cracking is effected under such conditions in a period of time ranging from about 15 seconds to hours although longer periods can be used. 'It is preferable to effect thermal cracking at a temperature from about 300 to 400 C. in a time period from about 3 to 30 minutes. Thermal cracking can be conducted in any vessel or reaction zone which can maintain the terpolymer in the noted temperature range. Alternatively, the terpolymer can be dissolved in a carrier, such as mineral oil, and the mixture treated as above to crack the terpolymer. Cracking the terpolymer in a mineral oil carrier gives a pour depressant-oil mixture which is convenient to handle and use.

The pour depressant of the invention can also be prepared by catalytically cracking the terpolymer of prescribed composition. The terpolymer is contacted with a cracking catalyst at an elevated temperature, generally in the range of 150 to 400 C. until an amorphous, cracked terpolymer having an inherent viscosity in the range of 0.2 to 0.9 is produced. Catalysts which are effective for cracking the terpolymer include the Friedel- Crafts catalysts, Fullers Earth, silica alumina, chromia alumina, molybdena, bauxite, silica magnesia and catalysts generally effective for cracking petroleum streams.

The pour depressant of the invention is employed in middle distillate mineral oils in a concentration ranging from about 0.001 to 1 weight percent. The preferred concentration of the pour depressant in an amount in the range of 0.005 to 0.05 weight percent which corresponds to about to 150 PTB (pounds per thousand barrels).

The following examples illustrate the preparation of the pour depressant of the invention and their effectiveness for lowering the pour point of the middle distillatefuel oils.

EXAMPLE I An ethylene-propylene gas mixture in the proportion of 2.16 moles of propylene per mole of ethylene was scrubbed by passing the mixture through a packed tower in contact with 50% aqueous potassium hydroxide and thereafter dried in a tower packed with Drierite. The dry gas mixture was passed into 400 ml. of purified nheptane to saturate the solvent which was maintained at 40 F. After saturating the solvent, the gas mixture was continuously fed into the solvent at a rate of 1.0 liter per minute. A third reactant, hexadiene-l,5 in the amount of 0.4 gram was added to the solvent containing the reaction mixture. Polymerization was initiated with catalysts. Catalyst A was a solution of diethylaluminum chloride in n-heptane. Catalyst B was a 20% solution of tnbutylvanadate in n-heptane. /2 cc. of Catalyst A and /.2 cc. of Catalyst B were added to the reaction mixture to initiate polymerization. After two minutes, an additional /2 cc. of Catalyst B was added to the reaction mixture. The polymerization was completed after 10 min.

The terpolymer produced was recovered from the solvent by treating the mixture with several portions of methanol. The precipitated and separated terpolymer was then treated with an additional quantity of methanol to remove any remaining n-heptane and dried on a steam plate. Infrared analysis of the product established that the terpolymer was amorphous. The inherent viscosity of the ethylene-propylene-terpolymer at 0.08% in toluene at 100 F. was 1.69.

A portion of the terpolymer product was heated in a test tube at 667 F. (353 C.) for 5 minutes. This caused thermal cracking of the terpolymer material. Infrared analysis of this product showed that the cracked terpolymer was amorphous. The inherent viscosity of the cracked polymer at 0.08% in toluene at 100 F. was 0.50.

4 The pour depressant effect of the cracked terpolymer of the invention and of the starting terpolymer prepared above were compared by testing the additives for their pour depressant properties in a middle distillate mineral oil having the following inspection values:

Specifications for middle distillate fuel The additive materials were used at a concentration of PTB (pounds per thousand barrels). The ethylenepropylene-terpolymer prior to cracking reduced the pour point of the middle distillate to 35 F. In contrast, the cracked terpolymer product of the invention reduced the pour point of the middle distillate to '55 F.

EXAMPLE II An ethylene-propylene gas mixture in the proportion of 1.92 moles of propylene per mole of ethylene was scrubbed and dried as in Example I and then passed into 2000 ml. of purified n-heptane maintained at 39 F. After saturating the solvent, 2 ml. of dicyclopentadiene was added while continuously feeding the ethylene-propylene gas mixture at a rate of 2.0 liters per minute. A mixture of 2 cc. of Catalyst A and 1 cc. of Catalyst B, described in Example I, were added to the polymerization reaction mixture to initiate the polymerization reaction. After the reaction proceeded for three minutes, an additional 2 cc. of Catalyst A was added to the reaction mixture. The reaction was completed after 18 minutes.

The terpolymer reaction product was recovered from the solvent mixture in the manner described above. Infrared analysis of the terpolymer polymerization product established that this was an amorphous terpolymer. The inherent viscosity of the terpolymer at 1% in toluene at 100 F. was 1.16 and the iodine number 8.34.

A portion of the terpolymer polymerization product was heated to 670 F. for a period of 9 minutes to thermally crack the terpolymer and produce the pour depressant of the invention. Infrared analysis of this product showed that the cracked polymer was amorphous in nature. The inherent viscosity of this product was 0.300 and the iodine number 12.9.

The pour depressant effect of the cracked terpolymer of the invention and of the starting terpolymer prepared above were compared for their pour depressant properties in a middle distillate mineral oil having a pour point of 10 F. At a concentration of 100 PTB, the terpolymer raised the pour point of the oil to 0 F. In contrast, the cracked terpolymer in the same concentration reduced the pour point of the oil to 70 F.

EX'AMPLE III An ethylene-propylene gas mixture in the proportion of 1.82 moles of propylene per mole of ethylene was scrubbed and dried as in Example I and was passed into 1000 ml. of purified n-heptane maintained at 38 After saturating the solvent, 2 ml. of hexadiene-1,5 was added while continuously feeding the ethylene-propylene gas mixture at a rate of 2.0 liters per minute. A mixture of 5 cc. of Catalyst A and 1 cc. of Catalyst B, described above, were added to the polymerization reaction mixture to initiate the polymerization reaction. After 3 minutes an additional 2 cc. of Catalyst A and /2 cc. of Catalyst B were added. After another minute and a 4 minute intervals thereafter for a total of 4 times, an additional one ml. of hexadiene-LS were added to the reaction mixture. At '6 minutes from the beginning of the reaction, an additional 2 cc. of Catalyst A and A2 cc. of Catalyst B were added. The reaction was completed in 30 minutes.

The terpolymer reaction product was recovered from the solvent mixture according to the method described in Example I. Infrared analysis of the terpolymer polymerization product showed that this was amorphous. The terpolymer had an inherent viscosity at 1% in toluene at 100 F. of 1.16 and an iodine number of 1.05. A portion of the terpolymer polymerization product was heated to 670 F. for a period of 9 minutes to thermally crack the terpolymer and produce the pour depressant of the invention. Infrared analysis of the cracked product showed that the cracked terpolymer was amorphous. The inherent viscosity of this product at 1% in toluene at 100 F. was 0.540.

The pour depressant effect of the cracked terpolymer of the invention and of the starting terpolymer were compared and tested for their pour depressant properties in a middle distillate mineral oil having a pour point of 10 F. At a concentration of 100 PTB, the starting terpolymer reduced the pour point of the oil to 40 F. In contrast, the cracked terpolymer reaction product in the same concentration reduced the pour point of the oil to -70 F.

In an alternate method of processing, 1000 ml. of HClwashed polymerization reaction product in solvent (cement) containing the terpolymer Was placed in a flask together with 30 gm. of a parafiinic mineral oil (flash point 435 F., kin. vis. at 210 F., 39 cs., at 100 F. 97 cs). The mixture was stripped of heptane and the residue heated to a temperature of 680 F. and held at this temperature for 7 minutes. Analysis by dialysis showed the product to be 50 weight percent polymer. At a concentration of 100 PTB of this 50 weight percent cracked polymer-mineral oil mixture, the pour point of the middle distillate mineral oil of the example was reduced to -50 F.

Obviously many modifications and variations of the invention, as hereinbefore set forth, may be made with out departing from the spirit and scope thereof, and therefore only such limitations should be imposed as are indicated in the appended claims.

I claim:

1. A method for preparing a composition having pour depressant properties which comprises reacting a mixture of ethylene/propylene and a diene, selected from the group consisting of bicyclo[2,2,l]hepta-2,5-diene, 1,4- cyclohexadiene, 1,5-cyclooctadiene, dicyclopentadiene, di-isopropenyl benzene, dipentene, 2,2-dimethyl-1,5-hexadiene, 1,5-heptadiene, 1,5-hexadiene, 2-methyl-1,4-cyclohexadiene, methyl cyclopentadiene dimer, S-methylene-Z- norbornene, 3-methyl-1,5-heptadiene, 2-methyl-1,5-hexadiene, 3-methyl-1,5-hexadiene, 1,7-octadiene, 1,4-pentadiene, 4-vinyl-1-cyclohexene, and 2-methyl-l,4-pentadiene, in mole proportions ranging from 10 to 90 mole percent ethylene, 5 to mole percent propylene and 0.1 to 20 mole percent of said diene, under polymerization conditions in the presence of a polymerization catalyst to produce an amorphous terpolymer having an inherent viscosity in the range of 1.1 to 5, recovering said terpolymer and subjecting said terpolymer to thermal cracking conditions at a temperature about 353 C. until a cracked terpolymer having an inherent viscosity in the range of 0.2 to 0.9 is produced.

2. A method for preparing a pour depressant according to claim 1 in which said ethylene-propylene-terpolymer consists of 50 to mole percent ethylene, 5 to 45 mole percent propylene, and 1 to 5 mole percent diene.

3. A method according to claim 1 in which the diene in said terpolymer is hexadiene-l,5.

4. A method according to claim 1 in which the diene in said terpolymer is dicyclopentadiene.

References Cited UNITED STATES PATENTS 2,835,659 5/ 1958 Guillet 260-93.7 3,519,609 7/ 1970 McConnell 260-882 3,230,288 l/ 1966 Henderson 264-176 3,316,231 4/ 1967 Canterino 260-937 OTHER REFERENCES Brown, James E.; Tryon, Max; Mandel, John: Determination of Propylene in Ethylene-Propylene Copolymers by Infrared Spectrometry (1963), Analytical Chemistry, vol. 35, pp. 2172-6.

Madorsky, Samuel L.: Thermal Degradation of Organic Polymers, Interscience Publishers, Div. of John Wiley & Sons Inc., New York, NY. (1965), pp. 112-114.

JOSEPH L. SCHOFER, Primary Examiner R. S. BENJAMIN, Assistant Examiner US. Cl. X.R. 

